Composite container

ABSTRACT

A composite container for the storage of material. The composite container including a carton body constructed to define a enclosure. The enclosure coated on one surface with a heat sealable material. Secured to the coated surface of the enclosure is a cap portion.

FIELD OF THE INVENTION

[0001] The invention relates generally to containers and more specifically to sealable composite containers. These sealable composite containers are commonly used to store and transport perishable goods, such as cereals, baking goods, juice or other liquids.

BACKGROUND OF THE INVENTION

[0002] Sealable containers such as cereal boxes or juice cartons are designed to allow the user to open and reseal the container as often as required to exhaust the contained product. These sealable containers are commonly used to store and transport perishable goods, such as cereals, baking goods, juice or other liquids. The challenge faced when designing a sealable container is to create an inexpensive container that limits the exposure of the goods to the air, which causes the goods to become stale or spoil, while making it easy for the user to open and dispense the goods.

[0003] A typical sealable container is constructed from a single sheet of stiff paper scored and folded to create an enclosure which is secured by gluing opposing edges of the sheet together. Complicated overlapping layered designs are used in an attempt to eliminate pin holes or voids in the corners of the enclosure that are created during manufacture. Often, these difficult to produce overlapping designs are insufficient to create a airtight or watertight seal. To overcome this problem the interior surface of the enclosure can be coated with a thermoplastic film or a heat sealable bag can be added to protect and secure the contents of the container. In order to open a container sealed in this manner, the end user must breach the container's seal by pulling or cutting the heat sealed edges of the container or sealable bag. Once the container has been opened and the seal breached, there is no way for the end user to reseal the container and prevent the contents from being exposed to the air.

[0004] In order to construct a container that can be opened and resealed some containers have integrated a fixture, such as a plastic screw top in a juice carton, that allows the end user to open and reseal the container as needed. However, this configuration requires additional manufacturing steps and/or material to insure the integrity of the sealable container and as a result the container is more expensive and difficult to manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005]FIG. 1 is a perspective view of a composite container assembled in accordance with the teaching of a preferred embodiment of the invention;

[0006]FIG. 2 is an exploded view in perspective of the composite container illustrated in FIG. 1;

[0007]FIG. 3 is a sectional view of the composite container illustrated in FIG. 1 taken along section line A-A;

[0008]FIG. 4 is a perspective view of the composite container where one side has been formed to integrate a pour spout;

[0009]FIG. 5 is a perspective view of the composite container where one side has been formed to integrate a hand grip;

[0010]FIG. 6 is a perspective view of the composite container where one side has been formed into an extended transparent cap;

[0011]FIG. 7 illustrates the bottom of the composite container shown in FIG. 6;

[0012]FIG. 8 is a perspective view of a cylindrical composite container assembled in accordance with the preferred embodiments of the invention.

[0013]FIG. 9 illustrates the bottom of the cylindrical composite container shown in FIG. 8; and

[0014]FIG. 10 illustrates a composite container integrating a single formed end cap.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] A container constructed in accordance with a preferred embodiment of the present invention includes one or two thermoformed end caps and a foldable carton coated, at least partially, with a material compatible with the end caps. The heat causes the compatible material of either the end cap or the coated carton to melt and join together. A bond can be formed by melting one of the compatible materials and joining it to the other, but it is preferred to use an ultrasonic generator to melt both of the compatible materials to form a weld. In the process a continuous seal between the end cap and the coated carton is formed, thereby creating a completely sealed container with a coated interior. The resulting container is an amalgam of thermoformed plastic and coated paper that is easy to manufacture and requires less raw material, while providing an airtight and/or watertight container.

[0016] Additional benefits and feature of the invention will be apparent to those skilled in the art after reviewing the teachings illustrated by this detailed description of several preferred embodiments. The following description of the preferred embodiments is not intended to limit the scope of the invention to the precise form or forms detailed herein. Instead, the following description is intended to illustrative of the principles of the invention so that others may follow its teachings.

[0017] Referring now to the drawings, a sealable composite container is shown in FIGS. 1-3. The composite container 10 includes a carton 12, a lid 14 and a base 16. The carton 12 is constructed of stiff paper, such as cardboard, having a interior surface 18 coated with a themoplastic film 20, as seen in FIG. 3. The lid 14 and the base 16 are formed from a thermoplastic material compatible to the thermoplastic film 20 coating the interior surface 18. The compatible thermoplastic materials have similar melting points, such that when heat is applied, preferably using an ultrasonic generator, the thermoplastic materials will form a continuous weld 22 between the two surfaces. To aid in the formation of the weld 22, the lid 14 and the base 16 are formed to include a flange 24, as seen in FIG. 3, which increases the contact area between the compatible materials of the lid 14, the base 16 and the thermoplastic film 20.

[0018] Additionally, the lid 14 is formed with a discharge passage 26 and a resealable cover 28. The discharge passage 26 includes a bonding surface 30 to which a freshness seal (not shown) is secured. Upon removal of the freshness seal the product can be pour from the carton 12 through the discharge passage 26. When finished dispensing the product the resealable cover 28 can be closed to prevent the product from being continuously exposed to the air.

[0019] FIGS. 4-10 illustrate alternate preferred embodiments of the present invention. FIGS. 4 and 5 exemplify a composite container 40 having a carton 12, a pour side 32 and a handle side 34. The carton 12 is constructed in the same manner as described above. The pour side 32 and the handle side 34 are formed from a material compatible to the thermoplastic film 20 that at least partially coats the interior surface 18 of the carton 12. In the same manner as described above, the pour side 32 and the handle side 34 are formed with a flange 24 that facilitates the attachment of the sides 32, 34 to the carton 12 along weld seam 22.

[0020] The carton 12 is oriented such that the interior surface 20 is accessible from the sides, rather than from the top as illustrated in FIGS. 1-3. The pour side 32 is formed with an integral spout 38 and a resealable cover 16. A freshness seal (not shown) is secured to a bonding surface 18 after the product has been introduced into the carton 12 and prior to dispensing by the end user. Upon removal of the freshness seal the carton 12 can be tilted using the handle 36 integrally formed in the handle side 34, and product is easily dispensed from the spout 38 integrally formed in the pour side 32. When the end user has dispensed a desired amount of product the resealable cover 16 can be closed to prevent the product from being further exposed to the air.

[0021] Turning now to FIGS. 6-7, the internal volume of the carton 12 is increased by uniformly increasing the dimensions of the carton cap 40 beyond the boundary defined by the carton 12 enclosure. The end cap 16, shown in FIG. 7, is welded in place using the flange 24 to join the end cap 16 to the thermoplastic film 20 coating the interior surface 18 of the carton 12.

[0022] The cylindrical composite container 42 illustrated in FIGS. 8 and 9 is constructed from a single piece if stiff paper to form a cylindrical enclosure 48. The container 42 incorporates the cylindrical enclosure 48, a rounded cap 44 and a rounded base 46. The rounded cap 44 includes a resealable cover 16 that can be used to seal the cylindrical container 42 after use. Both the rounded cap 44 and rounded base 46 extend beyond the enclosure defined by the cylindrical enclosure 48.

[0023] The hybrid carton 50, shown in FIG. 10, incorporates a thermoformed end cap 14 into an enclosure constructed using overlapping flaps 52 to form the base.

[0024] Those skilled in the art will appreciate that, although the teachings of the invention have been illustrated in connection with certain embodiments, there is no intent to limit the invention to such embodiments. On the contrary, the intention of this application is to cover all modifications and embodiments fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents. 

What is claimed is:
 1. A container apparatus for the storage of material, comprising: a carton body portion defining an enclosure; a heat sealable material coating a surface of the enclosure; and at least one cap portion continuously secured to the surface by the heat sealable material.
 2. The container of claim 1, wherein the heat sealable material and the cap portion are the same material.
 3. The container of claim 2, wherein the heat sealable material and the cap portion comprise a thermoplastic material.
 4. The container of claim 3, wherein the thermoplastic material comprises a low density polyethylene material.
 5. The container of claim 1, wherein the heat sealable material extends over substantially an entire surface of the carton.
 6. The container of claim 1, wherein the carton body comprises stiff paper.
 7. The container of claim 1, wherein the cap portion is formed in the shape of a pour spout.
 8. The container of claim 1, wherein the cap portion is formed in the shape of a handle.
 9. The container of claim 1, wherein the cap portion forms a side of the enclosure.
 10. The container of claim 1, wherein the cap portion forms a top of the enclosure.
 11. The container of claim 1, wherein the cap portion is two pieces forming a top and a bottom of the enclosure.
 12. The container of claim 1, wherein the enclosure is substantially cylindrical.
 13. The container of claim 1, wherein the enclosure is box shaped.
 14. The container of claim 1, wherein the cap portion is formed to include a pattern.
 15. The container of claim 14, wherein the pattern is text.
 16. The container of claim 1, wherein the cap portion is printed to display a pattern.
 17. The container of claim 1, wherein the cap portion if formed to integrate a threaded screw top.
 18. The container of claim 1, wherein the cap portion is formed to include a reseable flap.
 19. The container of claim 2, wherein the cap portion and the heat sealable material are welded together.
 20. The container of claim 19, wherein the weld is created using an ultrasonic generator.
 21. The container of claim 1, wherein the cap portion and the heat sealable material are bonded together.
 22. The container of claim 1, wherein the cap portion extends beyond the enclosure to increase the volume of the container.
 23. A receptacle for the storage of material, comprising: a body portion defining an enclosure, the enclosure folded to form a first end and a closed second end; a heat sealable material coating a surface of the enclosure; a cap portion secured to the first end by the heat sealable material and the second end.
 24. A method of constructing a container, the method including the steps of: providing a carton body defining an enclosure; coating the carton body with a heat sealable material; and securing a cap portion to the carton body to seal the enclosure. 